On my 83 6.2 how do I hook up a manual push button in so that the glow plugs still come on as normal but I have a back up for when they won't come on. I have 60G's in it so they won't swell up, but in the winter it doesn't start as good as it did with 11g's. Any help would be nice because in the summer the controller won't turn them on when the truck is warm but some times it is cool enough that it should.

When the engine is warm then you don't need the glow plugs. And yes you can install a manual switch to operate the glow plug relay manually. Make sure your toggle switch is a momentary one so you can't accidentally leave it on. All you need to do is get 12V power to the + side of the relay thru a switch. I connected my wire before the temp switch in the right rear head so that the glow plugs will not come on if the engine is warm. I use Delco 60G's, but I still don't want to power them up if the engine is warm.

You will need the following items:

About 5 or 6 feet of wire. About #18 but you can get by with smaller if you must.
Some ring terminals. I do not know what size but they will be used on the control studs of the glow plug relay.
A push button MOMENTARY (normally open) switch. NO NOT, repeat DO NOT use a switch that can be turned on and left on. That is a sure way to fry your glow plugs.
A multimeter or you can get buy with a 12 volt test light.
Some small wire ties.


Proceed as follows:

Locate the glow plug controller. It is located near the place where the distributor would be on a gas engine. It sort of looks like a big spark plug with a large black oval connector on the top of it.
Remove the connector from the glow plug controller.
Wire tie the connector and wiring to a convenient location to keep it from flopping around and getting into or against anything it shouldn’t.
Locate the glow plug relay. It is usually located on or around the front fender well on the driver’s side. It is a cylinder about 2 ½ inches tall and about 1 ½ inches in diameter. It has 4 wires connected to it. Two of the wires are very heavy, about #8’s. One of the wires will go to the battery. The other two wires will be small control wires and will have a single black plastic connector.
Remove the black plastic connector.
Turn the ignition switch to RUN.
Using your multimeter set to a range that will read 12 volts DC, ground one of the meter probes. Using the other probe, probe the connector. Locate the wire that DOES NOT have 12 volts on it. If you are using a test light, it will be the wire that DOES NOT light the light.
Turn the ignition switch to OFF.
Disconnect BOTH batteries. Remember, negative first on both batteries.
Determine which terminal on the glow plug relay the wire that DOES NOT have 12 volts on it goes to. This is the terminal you will connect your new wire to.
Run your new wire through the fire wall and bring it out on the driver’s side of the instrument panel.
Remove the nuts on the glow plug relay that hold the spade lug connectors. Mine has 2 plastic nuts, a clear plastic shield and then two brass nuts.
Place one of your wring terminals on the end of your new wire on the engine side.
Secure the ring terminal under the nut that DOES NOT have 12 volts on it on the glow plug relay.
Reinstall the remainder of nuts and shield if equipped.
NO NOT reattach the connector on the glow plug controller at this time.
Locate where you are going to place your push button switch and make what ever preparations are required to mount the switch.
Attach your new wire to one of the terminals on the switch.
Locate a ground point that you can place a ring terminal on.
Run a piece of wire from the other terminal of your switch to the ground point.
Mount the switch.




CAUTION - NOTE – WARRINING

If at any time while reconnecting the wiring, including the batteries you hear the glow plug relay energize, DISCONNECT THAT CONNECTION IMMEDIATLY! If the glow plugs are engaging with out the push button being pushed, something is wrong and corrective action is required.





Reconnect the batteries.
Reconnect black plastic connector on the glow plug relay. When making this connection, if you hear (or feel) the glow plug relay energize, remove the connection immediately.
Using wire ties, secure the wiring for the new glow plug switch.
Test the circuit by turning on the ignition and pressing the new glow plug switch. The glow plug light should light and you should hear the glow plug relay click.


NOTE

Be sure you do not hold the glow plug switch longer then 8 seconds or glow plug damage could result.

ag4gt: In doing this you would use the 11g's ?

Use this system with 60g's and hold as long as needed as 60g's are self limiting and will not burn out from leaving them on too long. They do however require more glow time than 11g's.

Thanks for the help. Doing this the glow plugs will still work as normal when the controller turns them on correct? I know that the controller is only supposed to turn them on when it thinks it needs to, but sometimes it doesn't turn them on and I need them.

It will work right until it doesn't want to. The controllers on 83's were less than reliable and not worth replacing. If you do want to replace it replace it with a later model controller.:grd:

Thanks, what year did they make the switch to the better controller?